Transcript Making and Viewing Tolerances

STEP Tools, Inc.
T24 STEP-Manufacturing Meeting
Boeing Renton – May 14
Mitutoyo Kirkland – May 15
SC4 Parksville – May 18, 19, 20
Machining demonstrations at Renton
Touch Probe and Laser Scan
measurements at Kirkland
Technical Meetings at SC4
© Copyright 2009 — STEP Tools, Inc.
Slide 1
Attendees
STEP Tools, Inc.
Martin Hardwick
STEP Tools Inc
David Odendahl
Boeing Company
Mikael Hedlind
KTH
Magnus Lundgren
KTH
Frederick Proctor
National Institute of Standards and Technology
Sid Venkatesh
Boeing Company
Rich Morihara
Boeing Company
Brian Kindilein
CCAT
Eric Tingle
Mitutoyo
Barry Saylor
Micro Encoder
Dahai Yu
Micro Encoder
Gary Olson
Micro Encoder
Michael Nahum
Micro Encoder
Ben Jones
Micro Encoder
Dave Lawrence
Puget Sound Naval Shipyard
Lynn Frei
Puget Sound Naval Shipyard
Ben Baca
Puget Sound Naval Shipyard
Rick Woods
Helilical Solutions LLC
Jim Alfred
Application Specialties Inc.
Leon Xu
Boeing Company
Aydin Nissehi
University of Bath
Long Xiang
GE Fanuc
© Copyright 2009 — STEP Tools, Inc.
Slide 2
Meeting goals
STEP Tools, Inc.
• Have multiple sites machine the same part from
the same AP-238 data
– Find the issues
– Fix the problems
• Show AP-238 can be used for molds
– Large program files
– Short moves
– High surface finish
© Copyright 2009 — STEP Tools, Inc.
Slide 3
Summary of accomplishments
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STEP Tools, Inc.
Fanuc implementation of AP-238 STEP-NC
AP-203 e2 annotation tolerances read from Catia
Measured at Mitutoyo using laser scanner and touch probe
Moldy parts made from AP-238 data
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Boeing, USA
NIST, USA
CCAT, USA
Al’s Rod shop, USA
KTH, Sweden
Scania, Sweden
U. Bath, UK
© Copyright 2009 — STEP Tools, Inc.
Slide 4
Organization
Original Data Source
Tweaks/Issues
Machine Configuration
NIST
Mastercam 9
Periphery not finished. Poor
surface finish
DMG 70 3-axis mode
CCAT
Boeing Catia – 5 axis
Hand edits for tool changes.
Optimized feed and speeds
for Helical tooling
DMG e70 5-axis mode
Helical tooling
Al’s Rod Shop
Boeing Catia –
Simplified roughing
process
Hand edits to remove (0, 0
1) vectors and adjust feeds
and speeds
Tormach Machine Tool
($8,000)
Fred’s Controller
Scania
Boeing Catia
Hand edit speeds and feeds
to run slower and codes for
tool changing.
Hardinge 3-axis
Coromant tools
KTH
Boeing Catia
Divided program into
sections. Hand edit to
remove Traori commands
and adjust speeds and
feeds to run faster.
Tricept PKM 5-axis
Coromant tools
U.Bath
Boeing Catia metric
Not finished
Siemens 840D
3-axis Vertical
Bridgeport 8000R
Boeing 3-axis
Boeing Catia – 3 axis
Run as written
Okuma 3-axis
Boeing 5-axis
Boeing Catia – 5 axis
Run as written
Northwood Gantry
Fanuc Mixed Mode
Control
Results
STEP Tools, Inc.
CCAT
CCAT
Al rod
KTH
Scania
U.Bath
NIST
Boeing 3
Boeing 5
X
Al rod
Yes
X
KTH
Yes
Yes
Scania
Yes
Yes
Yes
NIST
Pass
Pass
Pass
Pass
X
Boeing
3-axis
Yes
Yes
Yes
Yes
Yes
Boeing
5-axis
Yes
Yes
Yes
Yes
Pass
X
X
U. Bath
© Copyright 2009 — STEP Tools, Inc.
X
Yes
X
Slide 6
Next steps
STEP Tools, Inc.
• Lessons learned
– We need to use chip load to drive speed and feed
Programmed Machine
Max Feed and Speed
Actual Machine
Max Feed and Speed
Feed
CAM
Feed
AP-238
Speed
Speed
Programmed
No. Flutes
Actual
No. Flutes
© Copyright 2009 — STEP Tools, Inc.
Slide 7
Next steps
STEP Tools, Inc.
• Lessons learned
– We need to change tool dimensions
– More data about the tools
» Stick–out (holder_base – tool_tip) – LUX in ISO 13399
» Minimum allowable flute length – max_depth_of_cut
» Tool holder dimensions
– Need more / clearer set-up information
» Origin, material
» As part of rawpiece definition?
– Variable elements that are realistic to change
» Utility to extract tool dimensions
© Copyright 2009 — STEP Tools, Inc.
Slide 8
Goals for next demonstration
STEP Tools, Inc.
• What
– Enable/Show round trip
– Mastercam ->AP-238-> Catia ->AP-238 -> FeatureCAM
– Multiple set-ups
• Use Moldy again
– Improve documentation so more can participate
» Setup information – annotate origin
» Tool stick-out, #flutes, flute length
» Max feed and speed
» Operation cycles for drilling
– Participation Rules
» Must be from single STEP-NC data source
» Must meet tolerances defined for the part
• Develop new part – Boxy
– Test/Prove-out multiple setup
– Accuracy, documentation, canned cycles
© Copyright 2009 — STEP Tools, Inc.
Slide 9
Moldy in Bath
STEP Tools, Inc.
• Faster machining by changing step over
• Metric – 3 axis
• Improve portability
– Feed speed approximation using spindle power
– Eliminate ¾ inch zero radius cutter
– Single hole size
» Describe most accurate process
» Describe required tolerances
» Describe process parameters such as peck cycles
» One hole size = 0.25 inch aka 6.35 mm
» Tell users they can reduce the process if they maintain the
tolerances
© Copyright 2009 — STEP Tools, Inc.
Slide 10
Moldy Deadlines
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STEP Tools, Inc.
CAD/CAM deadline - May 29th
Development Partners* commit – June 1st
First machining – June 15th
Machining Partners** commit – July 1st
Machining deadline - August 1st
Touch Probe results - September 4th
*Development partners are organizations with STEP-NC Experience
**Machining partners are new to STEP-NC
© Copyright 2009 — STEP Tools, Inc.
Slide 11
Boxy in Bath
STEP Tools, Inc.
• Use multiple CAM systems to make data
– Mastercam for setup 1 and 4
– Catia for setup 2
– FeatureCAM for setup 3
• Practice multiple setups
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Communicate origin to operators
Metric part and tooling
Tolerances on each part for each set-up
Different CAM for each setup
Four setups
No tool larger than 12mm
© Copyright 2009 — STEP Tools, Inc.
Slide 12
Boxy Deadlines
STEP Tools, Inc.
• CAD deadline - June 15th
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Setup 1 CAD
Setup 2 CAD
Setup 3 CAD
Setup 4 CAD
model – KTH Mastercam
model – Boeing Catia
model – U.Bath FeatureCAM
model – KTH Mastercam
Development partners commit – June 15th
CAM deadline – July 1st
Assembled data deadline – July 15th
Machining partners commit – August 1st
Machining – September 15th
© Copyright 2009 — STEP Tools, Inc.
Slide 13
Anticipated Participants
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STEP Tools, Inc.
NIST
Boeing
CCAT
KTH
Scania
U.Bath
Al’s Rod shop
Naval shipyards
Sandvik Coromant
GE Fanuc
Mitutoyo
Helical
© Copyright 2009 — STEP Tools, Inc.
Slide 14
Targeted Participants
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STEP Tools, Inc.
Rolls Royce – Aydin
Siemens - Stephen
U.Manchester - Stephen
Airbus – Martin
French Universities Paul Sabitier (via Alain), U.Metz (Aydin),
U.Bordeaux (via Alain)
Spirit (formerly Boeing Wichita) – David O
German Universities (Aachen, Stuttgart) - Stephen
Okuma – David O
Fatronik (machine tool company) - Aydin
MCM (controller company) - Aydin
Volvo - Magnus
Saab aerostructures - Mikael
Swiss Universities (EPFL) – Stephen
Korea Universities (Postech) – Stephen
Mitsibushi – David O.
© Copyright 2009 — STEP Tools, Inc.
Slide 15